Method for treating liquid materials

ABSTRACT

A method for treating a biological organism in a medium, comprising heating the medium containing the organism by a temperature of at least about 2° C. at a rate which exceeds a relaxation rate of a cellular membrane of that organism, under such time and temperature conditions which do not thermally denature a substantial portion of the biological proteins. A method is also provided for treating a biological organism in a medium, comprising heating the medium containing the organism by a temperature of at least about 2° C. at a rate which exceeds a relaxation rate of a cellular membrane of that organism, under such time and temperature conditions which do not thermally denature a substantial portion of the biological proteins.

The present application is a continuation of U.S. Utility patentapplication Ser. No. 09/411,088, filed on Oct. 4, 1999, now U.S. Pat.No. 6,410,284 which is a Continuation Application of application Ser.No. 08/812,109, filed on Mar. 5, 1997, now U.S. Pat. No. 5,962,288 forwhich claims benefit of priority for U.S. Provisional Application No.60/017,121, filed on Mar. 6, 1996.

FIELD OF THE INVENTION

The present invention relates to the field of methods and systems forflash heat treatment of liquid streams. More particularly, the presentinvention relates to food and pharmacological industries, tobactericidal treatment of liquid food products. The present inventionalso relates to the field of methods and systems for altering cells ortissues of organisms with high rate thermal changes. These alterationsare useful for developing medicines and for medical treatments.

BACKGROUND OF THE INVENTION

A number of methods are known for reducing bacterial activity inliquids. Traditionally, a so-called “Pasteurization” process isemployed, which operates by the principles of thermal denaturation ofproteins to inactivate bacteria. Thus, the liquid is raised to aparticular temperature for a proscribed duration, to effect astatistical reduction in the number of, or even elimination of allviable bacteria. In an effort to reduce a duration of the process, hightemperatures may be employed, which raise the temperature of the fluidto, e.g., 150° C. for 2–4 seconds under pressure, followed by a flashing(rapid boiling) to lower the temperature, thus limiting the duration ofthe treatment. Such systems thus require a very high temperature, andmay alter a taste of a potable liquid or food product, such as is thecase with milk. Depending on how the heat is applied, precipitation ofproteins in the product or other physical changes may occur. Inaddition, the presence of oxygen during treatment may cause acceleratedoxidation.

The heat treatment processes for fluid food products (e.g., milk) areapplied for destroying disease-causing microorganisms, as well asinactivating microorganisms which may spoil the food. In many knownprocesses, the bacterial reduction is a preservation technique whichextends the shelf life, but sterilization is not achieved. Some of thesepasteurization techniques involving heat treatment of food products, forinstance, milk, are disclosed in USSR Pat. No. N 463,250 M KI A 23c 3/02and N 427532 M KI 28 9/00 A 23c 3/02.

The most widely used Pasteurized technique involves subjecting foodproducts to heat treatment as high as 65–75° C. and exposing same tothis temperature for a period of time of 30 minutes. This is theso-called long-term heat treatment. The second technique involvessubjecting food products to heat treatment at a temperature of 70–75° C.and exposing same to this temperature for a period of time of 2–4minutes. The third technique involves subject food products to shortterm heat treatment at a temperature of 95° C. and exposing same to thistemperature for 30 seconds. The fourth technique includes ultra hightemperature heat treatment. It involves subjecting food products to atemperature of 110–140° C. and exposing same to this temperature for aperiod of time of 2–3 seconds. These treatment are thus based on athermostability time-temperature relationship of microorganisms.Thermostable life-time is defined as a life-time of microorganisms at agiven temperature. The higher the temperature, the shorter thethermostable period. A effective Pasteurization treatment thus subjectsfood products to heat treatment at a certain temperature for a period oftime which is longer than the thermostable period.

These prior art food processing techniques have the following drawbacks:

1. Heat treatment of food products involves a certain extent of vitamindestruction and denaturation of proteins, or even their coagulation.These factors affect the biological value of the products subjected topasteurization. It is important to note that the higher thetime-temperature product, the higher the extent of vitamin destructionand the extent of protein denaturation. This is one of the principalconstraints of the efficacy of pasteurization techniques, as it involvessimultaneous deterioration of the quality of food products subjected topasteurization process.

2. The taste of a pasteurized food product is changed from the originalone.

3. Certain food products being subjected to heat treatment producesediments. For instance, pasteurization of milk results in producingmilk “stone” which is very difficult to eliminate, which deterioratesheat exchange with a pasteurization heating system, causes “browning”and adversely affects milk taste. The milk sediment acts as a “breedingground” (an accumulator) for bacteria and may deteriorate the efficacyof pasteurization.

4. The release of sediments results in the requirement for regularcleaning of heat exchanging equipment using special acid- andalkali-based deterrents. This deteriorates the quality of the product aswell as the productivity of the equipment, and may be environmentallyhazardous.

These prior art techniques are generally directed toward the thermaldenaturation of essential cell elements, they effectively cook the foodproduct, including any biological organisms therewithin. Thus, inaddition to altering the taste of the food product, they also affect itscomposition, for example vitamin concentrations, and structure, forexample coagulating proteins or producing sediments. These sedimentsalso necessitate regular cleaning of the system, especially any highertemperature portions, such as heat exchange surfaces.

Some of these drawbacks can be avoided by using the direct heattreatment, which heats the product by way of direct contact of theproduct subjected to Pasteurization with the heating medium, forinstance, steam, rather than through a heat transferring surface of heatexchange equipment. This method eliminates release of the milk “stone”in the heating zone and lessens its appearance on other surfaces of theequipment. These known methods transfer the product into thePasteurizer, and inject steam made from potable water to a desiredtemperature, for a desired period. The product is cooled and excesswater from condensed steam eliminated. This technique allows arelatively quick heat treatment of the product, and has been found ofparticular use in ultra high temperature heat treatments. The techniqueavoids exposure to temperatures higher than a desired final temperature,and thus may limit sedimentation, which may appear, for example, as milk“stone” in a Pasteurization process. Where direct steam contact is used,it dilutes the medium, for example up to 30% of the product mass, withan ultra-high temperature Pasteurization technique, which subsequentlyis often removed.

These known methods of Pasteurization strive to maintain laminar flow ofmilk during the process, and thus do not atomize the milk. As a result,these systems fail to raise the temperature of the bulk of the milk at arapid rate, and rather gradually raise the bulk temperature to thePasteurization temperature, at which the milk is maintained for thedesired period. Of course, a small surface layer may experience rapidtemperature rises.

Zhang, et al., “Engineering Aspects of Pulsed Electric FieldPasteurization”, Elsevier Publishing Co. (1994) 0260–8774(94)00030-1,pp. 261–281, incorporated herein by reference, relates to PulsedElectric Field Pasteurization, a non-thermal Pasteurization method. Thismethod (as well as other biological treatment methods) may be combinedwith other methods, to enhance efficacy of the composite process, whileavoiding the limitations of an excess exposure to any one process.

PRIOR ART

RU 2,052,967 (C1) relates to a rapid temperature rise bactericidaltreatment method. Abrams et al, U.S. Pat. No. 3,041,958 relates to asteam processing temperature control apparatus. Wakeman, U.S. Pat. No.3,156,176 relates to a steam Pasteurization system. Stewart, U.S. Pat.No. 3,182,975 relates to a steam injection heater, which employsimpeller blades to mix steam and milk for rapid heating. Engel, U.S.Pat. No. 3,450,022 relates to a steam infuser for high temperature steamtreatment of liquids. Nelson, U.S. Pat. No. 3,451,327 relates to a steaminjector for a milk sterilizer. This device is intended to bring themilk to a high temperature, and thus allows thermal communicationbetween the steam and milk prior to venting. De Stoutz, U.S. Pat. No.3,934,042 relates to a system for treating beverages, including milk,beer, wine and fruit juices, for sterilization or Pasteurization. Theliquid is held at elevated temperatures for extended periods.Janivtchik, U.S. Pat. No. 4,160,002 relates to steam injectors forPasteurizing milk using pressurized steam. Wakeman, U.S. Pat. No.4,161,909 relates to an ultrahigh temperature heating system forheating, e.g., milk. The milk falls in a curtain configuration in asteam chamber. The milk is held at a high temperature after heating.Nahra et al. U.S. Pat. No. 4,591,463, and Nahra et al. U.S. Pat. No. Re.32,695, incorporated herein by reference, relate to a milk ultraPasteurization apparatus in which sheets of milk fall within a steamfilled chamber for ultra high temperature Pasteurization. Bronnert, U.S.Pat. Nos. 4,787,304 and 4,776,268 relate to an infusion heatingapparatus for sterilizing liquid food products, having a porous steamdispensing cylinder or diffuser located along a central axis of atreatment vessel. Sanchez Rodriguez, U.S. Pat. No. 5,209,157 relates toa diary preparation system which involves an ultrahigh temperaturetreatment step.

SUMMARY AND OBJECTS OF THE INVENTION

The present invention seeks to alter cell characteristics by a thermalshock process, which may be used, for example, to inactivate or killbacteria, alter cell surface chemistry or antigenicity, disruptmembranes, activate cell functions or responses, disaggregate cells, asa pretreatment before cell fusion or infection, activate or change thefunction of a cellular parasite (bacteria, mycoplasma, virus, prion,etc.), affect mitochondrial functioning or the functioning of otherorganelles. On an organism level, the present invention may be used totreat bacterial infections, such as osteomyelitis, viral infections suchas AIDS, human or animal Herpes viruses (including HHV-5 and EBV, aswell as CMV, HSV-1, HSV-2, VZV, HHV-8, and the like), treat cancer,sarcoma, mesothelioma, teratoma or other malignancy or neoplasm, treatskin conditions, such as psoriasis, treat inflammation, treat fungaldiseases, blood borne diseases, leukemias and the like. The presentinvention may also have utility in the treatment of syndromes, which maybe multifactorial in origin and involve an immunological component ordefect. Therefore, the present invention may also find utility in thetreatment of chronic fatigue syndrome (CFS), for example by applyingimmune stimulation therapy through treatment of blood or bloodcomponents.

The broad utility of the present invention comes from its ability tocarefully control a stress applied to a cell. This stress may, ofcourse, kill the cell or selectively kill a subpopulation of cells, butmore importantly, it is believed that the present invention may beapplied to cells to have a measurable non-transient effect which doesnot immediately result in cell death. In this manner, the present methodprovides a new manipulation modality for cells.

In contrast to known cellular thermal inactivation methods, the presentinvention does not rely on thermal denaturation of cellular proteins andenzymes, but rather on a rapid temperature rise which irreversiblychanges the cell, at temperatures and energy levels below those requiredby traditional Pasteurization processes.

In particular, the system and method according to the present inventiontreat a product such that the temperature of a medium in which all or aportion of the cells exist rises at such a rapid rate that normalaccommodation mechanisms, which might allow the cell to avoid permanenteffect from a slower temperature rise rate treatment, are unavailable orineffective. Thus, it is an aspect of the present invention to altercell functioning based on a rate of temperature change during treatment,rather than based on a time-temperature product function or a maximumtemperature.

The present invention is thus believed to operate by a physicalprinciple different than thermal denaturation, the principle behindPasteurization. Rather than a thermal denaturation of the proteins, aswell as proteins which may be in the extracellular medium, the presentinvention operates by thermal shock, which is believed to disrupt oralter membrane structures or membrane components of cells. Typicalfluids include milk, egg white, blood plasma, cell culture medium,fermentation broth, fruit juices, and the like

Thus, rather than a high temperature, per se, the present inventionrequires a high rate of temperature rise. The resulting maximumtemperature may be limited to temperatures which do not denature variousproteins, e.g., a maximum temperature of 0–75° C. It is clear,therefore, that the maximum temperature may remain sub-physiological, orrise to relatively high levels. For food processing, the maximumtemperatures will often be on the higher end of the scale, in the 40–75°C. range, while in medical or pharmaceutical process, the maximumtemperatures will often be in the middle of the range, e.g., 15–45° C.

There are a number of slightly different theories why thermal shock mayaffect cells, or more particularly membranes, membrane bound cellstructures or organelles. When the thermal shock is substantial,bacterial or spore killing is effected. Under gentler conditions,organisms may survive.

One theory of operation of the present invention relates to the glasstransition temperature of membrane structures. Cellular membranes aregenerally formed of phospholipid bilayers with proteins, lipoproteinsand glycoproteins inserted on the inside, outside, or protruding throughthe membrane. The membrane, especially the fatty acid chains of thephospholipids, are physiologically maintained in a fluid condition, andthus lipids and proteins are motile across the surface of the membrane.For example, under comparable circurmstances, a lipid molecule maytravel at a rate of about 2 microns per second, with proteins travelingat a rate of several microns per minute, in the plane of the membrane.Membrane components, though mobile in the plane of the membrane, aregenerally slow to switch or invert between the outer and inner surface.For example, transverse diffusion rate of phospholipids is about 10⁻⁹the rate of lateral diffusion, for a typical 50 Å distance (thethickness of a phospholipid bilayer membrane). The viscosity of a cellmembrane typically is about 100 times that of water.

On the other hand, the membrane structures of living cells have somelong-term ordering of molecules, especially the structures on thesurface of the membrane (as opposed to the lipid phase in the middle ofthe membrane), and therefore are in this sense crystalline. Thus, thephrase “liquid crystal” is apt for the composite structure. Among otherfunctions, the controlled membrane fluidity is believed to be necessaryfor various mediated transport systems which involve the movement ofcarriers within or through the membrane. The membrane proteins alsohave, in their natural state, a separation of charged and unchargedportions, allowing lipophilic portions of the proteins to be stablyinserted into the membrane structure, with hydrophilic portionsprotruding extracellularly or intracellularly from the membrane, intothe cytoplasm or extracellular fluid. Intracellular membranes may alsohave asymmetry. Since the phospholipids are essentially undistinguished,the long term (i.e., over distances of tens of Angstroms) ordering ofthe membrane along its surface is related to arrangements of the proteincomponents and the polar end-groups of the phospholipids. Some of theproteins or protein structures which extend through the membrane providechannels which allow ions, such as sodium, potassium and chloride toreadily cross, or to be selectively controlled or pumped. The size ofthe channel allows selectivity between differing ions, e.g., sodium andpotassium.

The tertiary configuration of the proteins (the three dimensionalstructure of a single protein molecule), and quaternary configuration ofpeptide structures (the spatial interaction of separate molecules) arethus critical for proper protein insertion in the membrane, and proteinfunctioning. Thus, the membrane is ordered, and this ordering relates toits function. A disruption of the ordering affects the cell function,and may destroy the cell, or have a lesser damaging, distinct orselective effect.

The membrane fluidity may be controlled by fatty acid composition. Forexample, bacteria use this mechanism. The fatty acyl chains of lipidmolecules may exist in an ordered, crystal-like state or in a relativelydisordered fluid state. The transition from the ordered to disorderedstate occurs when the temperature is raised above a “melting”temperature, or more properly, a glass transition temperature. In thecase of fatty acyl chains within the membrane, the physiological stateis fluidic. Of course, the membrane structure may have a number ofdifferent glass transition temperatures, for the various components andtheir respective energetically favorable orderings which may exist. Thisglass transition temperature depends on a number of factors, includingthe length of the fatty acyl side chain and their degree ofunsaturation. Unsaturation (with the naturally occurring cis-orientedcarbon-carbon bonds) causes “kinks” in the side chains, and increasesbond rotation on either side of the unsaturation, both of which impairorderly packing, thus reducing crystallinity and increasing the glasstransition temperature. Long fatty acyl chains interact more strongly,stabilizing the structure, and in increase in their proportion leads toa decrease in glass transition temperature.

It is known that in E. coli, the ratio of saturated to unsaturated fattyacyl chains in the cell membrane decreases from 1.6 to 1.0 as thetemperature decreases from 42° C. to 27° C. This decrease in theproportion of saturated residues is believed to present the membranefrom becoming too rigid at lower temperatures. Higher species, includingmammals, regulate cell membrane fluidity through cholesterol content,although this mechanism is believed to be absent in bacteria. It isbelieved that these membrane-composition accommodation mechanisms arecomparatively slow.

It is also believed that organisms, such as bacteria, maintain theircell membranes a number of degrees below an important glass transitiontemperature of the membrane, thus assuring a balance between membranefluidity and crystalline-like ordering. This crystalline state alsoimplies a non-linear response of the membrane to temperature variationsaround the glass transition temperature.

Cellular mechanisms are believed to be present which assure that,through commonly encountered temperature variations, irreversiblecellular damage does not occur. Some of these mechanisms are active orcontrolled, and thus have a latency. Some of these temperature changesmay also trigger physiological cellular responses, such as so-calledtemperature shock proteins. Some of these mechanisms are physical andpassive, and thus occur relatively rapidly These include stretching,membrane shape changes, and the like.

According to this theory, the system and method according to the presentinvention seek to take advantage of these delayed responses in theaccommodation mechanisms to temperature increases, by increasing thetemperature, through this glass transition temperature, at such a ratethat the cellular mechanisms do not have a chance to effectivelyrespond, thus allowing irreversible damage to the bacteria, presumablythrough a disruption of the higher levels of organization, withoutnecessarily affecting the lower organizational levels of structure.Thus, the temperature of the bacteria need not be raised to atemperature sufficient to thermally denature the tertiary structure ofproteins.

Another theory for the observed bactericidal effect, and indeed thesterilizing effect believed to exist, is that, though the temperature ofthe cells is raised, it is not raised sufficiently to completelyfluidize the membranes, leaving them comparatively stiff, brittle ornon-compliant. The thermal shock according to the present invention alsoproduces a mechanical stress, which may damage or affect the membrane.This damage may result in lysis, or a less severe mechanical disruption,which may later result in cell death or other response. This mechanicalstress may also activate cellular processes or otherwise influence cellfunctioning. This effect is essentially opposite to that seen in hightemperature Pasteurization (HTP), wherein the sustained highertemperatures tend to liquefy the membrane; although these HTP processesare specifically intended to thermally denature proteins to inactivatecells.

High temperature change rates are needed in order to prevent therelaxation of structural changes in a cell, e.g., the cellular membrane,which occur over approximately 10–100 mS. With temperature rise rates inexcess of this rate, an effect occurs, which may, for example, disruptor inactivate bacteria or cells or have other effects.

The induced thermal shock thus produces a number of effects on the cell.First, the cell rapidly expands due to the increase in temperature.Second, the cellular membranes may experience a configurational changeeither as a primary effect or secondarily due to a phase, volume orshape change of cellular components. Third, while thermal denaturationgenerally is directed to essentially irreversible changes in thetertiary protein structures of critical proteins and enzymes, thermalshock may effectively reduce quaternary organization to control or alterthe cell. Microtubule structures and nucleic acid conformations may alsobe affected.

According to the present invention, one method for inducing thiscontrolled yet rapid temperature rise is by treating medium containingthe cells, generally in relatively small droplets to provide a largesurface area to volume ratio and small thermal inertia, held at astarting temperature, with an excess of steam at the desired finaltemperature. The interaction between the droplets and steam is rapid,equilibrating within milliseconds at the final temperature, with only asmall amount of dilution due to the high latent heat of vaporization ofsteam. Generally, in order to reduce a rate-limiting boundary layer, thedroplets are degassed prior to treatment.

The water derived from condensed steam chemically dilutes the droplets,rather than mechanically diluting them. In the case of milk, this meansthat the water is associated with the milk proteins, and the treatmentdoes not substantially adversely affect the flavor of the milk. Thisexcess water may also be removed. In the case of biological media, thedilution is relatively small, and therefore is unlikely to induce ahypotonic shock. However, to the extent that this hypotonic shock doesinduce a response, that response forms a part of the present invention.

Alternately, other controlled addition of energy to the cell-containingmedium or tissue may be used. Thus, for treatment of human organs, apowerful microwave device may be used which heats the aqueous phase ofthe tissue. The energy of the microwave is controlled so that thetissues are heated to a desired temperature. The energy is appliedrapidly, in order to obtain the desired temperature rise rate, e.g., inexcess of 1000° C. per second, over a short period, which also meansthat thermal diffusion or blood perfusion become comparativelyinsignificant factors in the treatment. The volume to be treated may bephysically measured, estimated, or empirically determined by a “test”treatment which applies a relatively small amount of energy anddetermines the temperature rise in response. In any case, it isimportant to assure uniformity of treatment of bulk tissues, in order toprevent spatial variations in treatment. However, where the coal is nottreatment of all cells within the organ or tissue, for example and organsuch as lung, liver or brain, or a tissue such as a solid tumor, thenthe treatment may be directed toward a portion of the tissue, with caretaken not to over-treat any essential tissues. Thus, non-uniform ornon-uniform fields of microwaves or infrared radiation (coherent orincoherent, monochromatic or broadband) may be employed to heat cells ortissues.

In general, visible or ionizing radiation and acoustic waves are notpreferred energy sources because, in order to raise the temperature bythe desired amount, other effects will likely be produced in thetissues. However, where these other effects are desired orcomplementary, they may be employed.

A composite treatment may also be fashioned, in which a core tissue isdestroyed, while a peripheral shell is partially treated. It is knownthat one mechanism by which neoplastic cells escape normal immunologicalsurveillance is by hiding antigenic factors from the cell surface, oreven not producing certain antigenic markers. It is believed that thepresent invention will overcome these mechanisms are disrupt or altermembranes so that antigenic markers or elements are accessible. In thiscase, cell death is not necessary for efficacy, as the mere presentationof unique or characteristic antigens may be sufficient to spur animmunologic response which results in an effective treatment.

Blood presents certain interesting properties material to itsapplication for treatment according to the present invention. First, itmay be transferred to an extracorporeal reactor. Second, bloodcomponents may be separated in real time, in a pheresis process, andindividual blood components (erythrocytes, leukocytes, platelets,plasma, etc.) treated separately. Third, it is a liquid which maybeseparated into small droplets. Thus, blood treatment may be effectedthrough the “Pasteurizer” reactor, using treatment parameters which donot coagulate or denature blood proteins. Generally, a useful treatmentdoes not attempt to kill all blood cells, or one would simplyextravasate without reinfusion, or separate undesired cell componentsand not reinfuse undesired components.

Therefore, often a goal of therapy is either selective treatment of asubpopulation of the cells, or a non-lethal treatment appliednon-selectively to all or some of the cells present. In order to effecta non-lethal treatment, the temperature rise rate is controlled, and/orthe temperature rise and/or maximum temperature is controlled.

Blood treatments may be effective, for example, to treat CFS, AIDS,malaria, babesiosis, other viral, bacterial, fungal or parasiticdiseases, leukemias or other blood-borne neoplasms, blood dysplasias anddyscrasias, immune disorders and syndromes. Bacterial-associatedautoimmune mediated disorders, such as those related to spirochetes(syphilus, Lyme disease), as well as other autoimmune related diseases,such as rheumatoid arthritis and lupus, may also be subject to treatmentaccording to the present invention.

In some syndromes, viruses play a primary or ancillary role. Many typesof viruses have a lipid coat, which is, for example, derived from thecell membrane of a host cell before budding or lysis, generally withviral-specific proteins or glycoproteins. It is characteristic ofchronic viral infections that the viruses avoid vigorous immunologicalresponse by not presenting antigenic proteins, or by mimicking hostproteins. On the other hand, some chronic viral infections produce anautoimmune response which does not particularly target or eliminateviral infected cells. In either case, the temperature shock methodaccording to the present invention allows relatively mildreconfiguration of membranes, allowing normally unavailable antigenicmarkers of membrane proteins or intracellular proteins to be presentedto the host immune system. Thus, any disease which is characterized bydeficient or misdirected host immunological response is a candidate fortreatment according to the present invention. Accordingly, cells whichare accessible through the blood, skin or in particular organs may betargeted with the temperature shock treatment.

It is also noted that temperature shock may be used to redirect theactivities of a cell. For example, circulating immune cells may berefractory or hyperstimulated. A treatment according to the presentinvention may be used to “resynchronize” or reset cells to obtain anormal response. Thus, the present invention need not be directed to thetreatment or destruction of abnormal cells, but rather to the use oftemperature shock for a variety of purposes.

Since the treatment of an individual patient does not necessarilyrequire high throughput, other energy sources may be used, besides steamand microwaves, including general infrared, laser, maser, and chemicalsources. Therefore, for example, a stream of blood, or bloodcomponent(s), may be subjected to a controlled low power CO₂ laser ormicrowave treatment to effect the temperature shock treatment. Further,using cell separation techniques, such as those developed by CoulterElectronics, Hialeah, Fla., individual blood cells may be individuallytreated, based on an identification of type, and then, for example,reinfused into the host.

The cell treatment methods according to the present invention may alsobe applied to in vitro techniques in order to control cells or selectcell subpopulations. Typical applications include, for example, geneticengineering clonal selection for temperature shock resistance genes,which may be either a primary goal or a marker gene for a linked trait.

Another organ of interest is the skin, which may have tumors (malignantmelanoma, basal cell carcinoma, etc.), psoriasis, viral, bacterial orfungal infection, inflammation, other immunological or autoimmunedisorder, loss of elasticity, angioma, and other conditions. The skin isof particular interest because of the ease of external access to thesurface. Therefore, for example, a stream of steam, laser beam orinfrared source may be applied to the skin, in a manner which wouldquickly raise the temperature or the surface and possibly a region belowthe surface. In contrast to types of known treatments, the temperaturerise is carefully controlled, while the heating is nearly instantaneous.The careful control is exerted, for example in the case of steam, bycontrolling the partial pressure of the steam and performing thetreatment within a controlled environment, such as a hypobaric chamberor enclosure. In the case of laser, the pulse energy and repetitionrate, as well as particular wavelength of the laser, e.g., CO₂ with 10.6μm wavelength, may be empirically determined for an effective treatment.In the case of other electromagnetic waves, the field strength andduration of exposure are carefully controlled to effect a desiredtreatment.

Using a Pasteurization system according to the present invention, manylog reductions in E. coli were achieved, for example a reduction of from10⁶ per milliliter to the limit of detectability was achieved. Bacterialspores (B. subtilis) are also reduced, although possibly with lesserefficacy, for example a two log reduction (1% of original concentration)is achieved. It is believed that further refinement of the presentsystem and method will prove more effective against these spores, andprove effective to kill or produce a response in various types ofviruses, bacteria, fungi, protozoans, animal cells, and plant cells. Theexistence of organisms which survive treatment is clear evidence of thegentleness of treatment, and therefore that the treatment may bemodulated to effect various survival fractions, and selective treatmentof cell populations.

While strains which are desired to be treated may be found which areresistant to the system and method according to the present invention,supplemental methods may also be employed to treat the same medium, suchas pulsed electric fields, oscillating magnetic fields, electronionizing radiation, intense light pulses, actinic light or other visibleor ionizing electromagnetic radiation, and high pressure treatments.Thus, treatments may be combined to effect complete Pasteurization orsterilization or more selective cell changes. See, Zhang et al., supra,Mertens et al., “Developments in Nonthermal Processes for FoodPreservation”, Food Technology, 46(5):124–33 (1992), incorporated hereinby reference.

The parameters of a bulk medium steam treatment process which controlthe efficiency include starting and ending temperatures, rate oftemperature rise, degassing procedure (if any), pressure, pre- orpost-treatments, pH, droplet size and distribution, droplet velocity,and equipment configuration. Presently, systems operable for milkPasteurization have been tested using various parameters. For example atest has been conducted with a temperature rise from about 46° C. toabout 70.8° C., with a milk pH of 6.60 (start) to 6.65 (finish), and adilution of 2.5%. Droplet size is preferably about 0.2–0.3 mm. The rateof temperature rise is, for example, in excess of 1500° C. per second,and more preferably above 2000° C. per second. Under these conditions,with a starting bacterial and spore concentration of 10,000 spores perml, the final concentration was 12 per ml. Thus, a reduction of aboutthree logs was achieved under these conditions, without, for example,sedimentation of milk protein or noticeable alteration in taste.

Incorporated herein by reference is a report in Cyrillic, attachedhereto as an appendix, which provides background for the physicsinvolved in heating aqueous droplets of medium in a steam chamber.

The bulk medium steam treatment apparatus according to the presentinvention provides a rapid temperature rise by subjecting relativelysmall droplets of less than about 0.3 mm to dry steam(non-supercritical) at a partial pressure less than about 760 mm Hg. Forexample, with a low partial pressure of non-condensing gasses (e.g.,less than about 100 mm Hg, and more preferably below about 50 mm Hg),the partial pressure of steam is about 0.3–0.8 atmospheres (e.g., about225–620 mm Hg). The steam is saturated, and thus the temperature of thesteam is held at a desired final temperature, e.g., 40–75° C. The steamtemperature-pressure relationships are well known, and need not bereviewed herein.

Droplets of medium including cells to be treated are atomized underforce through a nozzle, into a reduced pressure reactor chambercontaining the steam. Under this partial vacuum, residual gasses aredrawn out of the droplet, which may form a boundary layer, reducing heattransfer rate; therefore, it is preferred that the bulk medium to betreated is degassed prior to treatment. Along its path, the dropletscontact steam, which condenses on the relatively cooler droplets andheats the droplets through release of the latent heat of vaporization.As the steam condenses, the droplets are heated, until they reach theequilibrium temperature of the steam, at which time there is no furthernet condensation of steam. The droplets will not get hotter than thesteam in the chamber, so that the steam temperature sets the maximumtemperature. However, depending on reactor configuration, the dropletsmay not reach equilibrium, and thus may reach a maximum temperaturesomewhat cooler then the steam. Of course, the initial interaction ofthe droplet with the steam will produce the highest temperature chancerate, so that the reactor system may be designed to operate at a steadystate which does not achieve equilibrium temperature. In this case,however, parameters should be tightly controlled to assure completetreatment without overtreatment, and thus a maximum temperature above adesired level.

The condensation of steam on the droplets induces pressure variations,or more properly steam partial pressure variations, within the reactor.In order to prevent a buildup of non-condensing gasses throughoutgassing or impurities, a vacuum pump may be provided whichcontinuously withdraws gas, with a port near the droplet injectionnozzle, removing the non-condensing gasses and some steam. Preferably,however, the product to be treated is fully degassed prior to entry intothe reactor, and thus there will be little or no buildup ofnon-condensing gasses which require evacuation from the reaction vesselduring processing. The droplet rapidly equilibrates with the steamtemperature under the pressure conditions, over a distance of less thanone meter, for example within 70 mm from the droplet injection nozzle.The so-treated droplets are then collected, and may be immediatelycooled, thus limiting any adverse effects of long-term exposure to thesteam temperature.

In one embodiment, the reaction vessel is provided with a number ofzones which maintain steady state distinction. For example, in aninitial portion, a low absolute pressure is maintained, degassing thedroplets. In a subsequent portion, the droplets are contacted withsteam, resulting in a rapid temperature rise of the droplets to effectthe desired treatment. In a final section, a low steam partial pressureis maintained, allowing vaporization of water from the droplets,allowing flash cooling. In this manner, the time temperature product maybe held at very low levels, effecting a rapid temperature increasefollowed by a relatively rapid temperature decrease. In order to provideseparate temperature zones within the reactor, an external energy sourcewithin the reactor may be provided, such as infrared radiation source,to maintain steam temperature. Zones may also be separated by baffleswhich allow droplets to pass, while providing a gas flow restriction.

The steam in the preferred embodiment is provided by a steam generator,which boils, for example, potable or distilled water. This water isdegassed prior to use, so that the steam contains few impurities andalmost no non-condensing impurities. The steam generator may be at anytemperature above the final temperature, e.g., 150° C., as the thermaltreatment of the droplets derives mainly from the latent heat ofvaporization of the droplets, and very little from the absolutetemperature of the steam. Preferably, the steam is saturated, which willdefine its temperature in a given atmosphere. If the steam issub-saturation, condensation of steam on the droplets will be impeded.If the steam is supersaturated, it will itself form droplets and impedethe process, in addition to diluting the medium. Process temperaturecontrol will also be adversely affected, and may be less predictable.

Thus, the mass flow rate of the saturated steam entering into thetreatment system (in relation to the product flow rate and anywithdrawal of steam or external heat transfer), controls the processtreatment temperature. In the case of an over-pressure steam generator,the mass flow rate is restricted to prevent the treated droplets fromreaching too high a temperature, or supersaturation conditions.

The steam is injected adjacent to the path of the droplets beingtreated, to ensure equilibration by the time the droplet reaches theterminus of the reactor. Due to boundary layer effects of the droplet,due to, for example, non-condensing gasses, as well as diffusionlimitations, the temperature rise is not instantaneous. However, usingthe system in accordance with the present invention, it has been foundthat temperature rise rates in excess of 2000° C. per second, or even7600° C. per second, may be achieved, which are sufficient to inactivatebacteria, and thus will effect may different types of cells and cellularstructures.

It is therefore an object of the present invention to eliminate thedrawbacks of ultra high temperature pasteurization processes with directsteam contact on foof products, namely: to improve the quality of theproducts subjected to pasteurization, to improve the quality ofpasteurization including reaching full sterilization, and to reducepower consumption.

It is another object of the present invention to provide a new treatmentmodality for disease, that of high temperature rate changes withoutnecessity of thermal denaturation.

It is a further object according to the present invention to provide amethod and system in which a rapid heat treatment is applied to the bulkof a product, with a temperature rise of several thousand degrees persecond. Preferably, the time and temperature conditions are insufficientto denature proteins, although this is not an absolute limitation.

It is a still further object according to the present invention to heata product at a rate sufficient to cause a thermal shock effect on cellscontained therein, reaching a final temperature for a period whichpreferably does not cause substantial thermal denaturation.

High temperature change rates are needed in order to overcome therelaxation rate of structural changes in a membrane structure, e.g., thecell membrane. A bacterial membrane, for example, relaxes over a periodof about 10–100 ms. Thus, where the temperature rise rate exceeds therelaxation rate, the membrane appears non-compliant, and is thereforeespecially subject to stresses which cause irreversible damage or atleast produce a non-transient effect. Therefore, the absolutetemperature rise as a result of the rapid heating should producesufficient stress to effect the cell in a non-transient manner. In thissense, non-transient means that an effect lingers after the treatment iscompleted and does not merely represent a reversible temperature inducedphysical effect.

Therefore, for example, the temperature rise should be at least about1–2° C. for a mild effect, and possibly 15–100° C. to assure cell deathor inactivation. Of course, the absolute temperature rise may depend ontemperature rise rate, as well as other reaction conditions. Generally,for cells of medical interest, the absolute temperature rise will beless than about 40° C., with a maximum temperature of less than 50° C.

The present bulk medium steam treatment apparatus according to thepresent invention therefore differs qualitatively from the known thermaldenaturation, (Pasteurization) processes and known medical processes.The quality of the product and efficacy of the process are not in directrelationship to each other, allowing an improvement in the efficacywithout detrimental effects.

Studies have shown that viable bacteria may be reduced or eliminated infoodstuffs, even to the limits of detectability, by a high rate oftemperature increase, and therefore such processes may be employed wheresuch bacterial reduction is desirable or required.

The preferred rate of temperature change for bacterial reduction is inexcess of about 2000° F. per second, and should be greater than about1100° C. per second. This rate of change is difficult to achieve througha direct contact process, where a mass of product to be treated is high,or the available surface area is low, due to the limits on thermaldiffusion through the surface layer and thermal inertia. However, the bypassing small liquid droplets through a controlled steam chamber, thedesired temperature rate of change may be obtained. It is noted thatsteam has a latent heat of vaporization of 540 cal/ml; therefore, a 5%ratio of steam to aqueous fluid to be processed will result in anapproximately 27° C. rise in temperature. The resultant 5% dilution maybe inconsequential, or remedied in a later step.

In the bulk medium steam treatment device, the medium is sprayed througha nozzle as a stream of small droplets into a reaction vessel. The sizeof these droplets is preferably less than 0.3 mm, though if the dropletsare too small they may present other difficulties, such as poortrajectory control, e.g., from low inertia, loss of velocity, e.g., dueto drag, Brownian motion, coalescence, and the like. Further, reduceddroplet size may reduce potential throughput. In addition, since, if thedroplet is too large, each drop of the medium may not be effectivelytreated, the droplet size distribution should include only a small umberof larger droplets, e.g. less than 1% of greater than 0.45 mm. Steam,which is produced in a steam generator, from, e.g., potable water, issupplied to the reactor vessel through a nozzle or array of nozzles.Steam condenses on the droplets, giving up its latent heat ofvaporization to the droplets. The magnitude of heat transfer duringcondensation is very high, so that the speed of heating reaches severalthousand degrees Centigrade per second. Therefore, in the severalmilliseconds it takes for droplets to travel through a reaction vessel,the temperature is raised substantially, effecting cellular alteration,e.g., bacterial inactivation, according to the present invention.

The steam is derived from a boiler. Tight control of temperature mayrequire a high temperature boiler with a control valve near the reactorvessel. In other words, in order to ensure adequate flow of steam intothe reactor, an excess capacity should be available from the boiler.Control is effected near the reactor, to avoid time response delays oroscillation. The water in the boiler is preferably degassed to eliminatenon-condensable components.

The steam is injected into the reactor vessel through a number of steaminjection ports, spaced along the path of the droplets within thechamber, so that the region distant from the fluid injection portmaintains a relatively constant water vapor pressure. Thus, depending onthe desired conditions, effective Pasteurization may be obtained with aslow as between 2–5% by weight steam, condensed on the fluid droplets toachieve the temperature rise. There are temperature gradients in thereactor chamber, primarily near the injection nozzle. Since the steamcondenses on the droplets, a partial vacuum is created in the regionaround the droplet, until the droplet reaches a temperature inequilibrium with the pressure, e.g., around 55° C. at 0.5 atmospheres,and thus the vapor pressure equalizes. At equilibrium, the netcondensation ceases, and the droplet remains in equilibrium.

The steam consumption is significantly lesser than in known ultra hightemperature Pasteurization processes. Assuming the temperature of heattreatment applied to milk is to 60° C. the temperature of milk uponentering the reaction vessel equal to 6–8° C., then the requiredtemperature rise will not exceed 55° C. It will require about 55 Kcalfor the heat treatment of one kilogram of fluid medium. As thecondensation heat of one kilogram of steam is equal to 540 Kcal (540cal/ml), only about 0.1 kilogram of steam will be required forcondensation, i.e., only 10% of the mass of the product subjected toprocessing. Obviously, lesser temperature rises will require less steam.

It is noted that there is no need to subject the product, for instance,milk, to heat treatment reaching a maximum temperature of 60° C.;however, higher temperatures may be reached if desired. Since it istemperature rise rate which is believed to be important, lower maximumtemperatures may be achieved. For example, bacterial inactivation hasbeen achieved even at a maximum process temperature of about 40° C.,thus making the requirement for steam consumption generally less than 7%of the mass of the medium undergoing Pasteurization.

The treated fluid medium, which has been slightly diluted withcondensate, is collected on the bottom surface of the reaction vesseland then is supplied through a special vent into the discharging tank.The collected medium is subjected to a vacuum treatment, evacuatinggases (air) and steam from the discharge, thus eliminating excessivewater, cooling the fluid medium through water evaporation, as possiblythrough an external cooling system. The fluid medium may then, forexample, constitute a final product or be used as part of a medicaltreatment.

The thermal shock treatment system has been tested for effectivePasteurization of milk and other fluids, in apparatus having aproductivity of up to 1000 kg/hour. The following substances weresubjected to Pasteurization: physiological solution, milk, egg melange,blood plasma. All of these fluent materials, prior to subjecting toPasteurization process, were disseminated with E. coli in aconcentration equal to 10⁷ per ml. After treatment, the concentration ofE. Coli either reached the lower limit of sensitivity of the method oftheir detection (0.0001%) or they were not detected at all, thusattesting to full sterilization process. There was no evidence of fluidprotein thermal denaturation. The E. Coli culture and the experimentalstudies of the Pasteurized products was prepared by the staff of theMicrobiological laboratory of the Medical Radiological Research Centerof the Medical Academy of Russia, using standard methods.

The experimental studies carried out have determined that, in order toproduce “Pasteurized” milk with a bacterial concentration not exceeding50,000 bacteria per ml (which corresponds to the grade 1 quality milk),from starting milk product with a bacterial concentration of 1–10million per ml, the heat treatment rate should be equal to or greaterthan about 1400° C. per second, and for producing sterilized milk, itshould be equal to or greater than 7600° C. per second. The maximumtemperature of sterilization does not generally require a temperature inexcess of 60° C., while retaining all the positive qualities of naturalmilk. Higher maximum temperatures may be employed.

One of the significant results reveals itself in the fact that due tolow temperature and short term heat treatment, it is also possible totreat such fluent products as egg white, even though such material issubject to coagulation upon reaching the temperature of 52° C.

Positive results have been achieved during blood plasma treatment. Thepresent invention can thus be utilized for Pasteurizing fruit andvegetable juices, wines, beer, yogurt produce, drinking water,pharmacological substances, etc.

The present invention provides efficacious treatment allowing fullsterilization of a fluid without substantially detrimentally thermallydenaturing proteins. It allows production of high quality dairy productsincluding baby food, the production of which has previously been underconstraints because of low quality Pasteurization. This is achievedthrough utilizing a new technique of incapacitating microorganisms and adifferent modality of destruction; high speed, short duration thermaltreatment.

The present invention:

1. requires heat treatment within a small temperature range, andtherefore is less power consuming.

2. allows the fabrication of treatment equipment free of heat transferapparatus, thus eliminating sediments on relatively hotter components,and thus eliminating necessity of its cleaning involving the usage ofchemical agents (acids and alkali).

3. allows the fabrication of both large-scale treatment equipment forplant installations with productivity of tens of tons per hour, as wellas small-scale treatment equipment or even reactors having a throughputof milliliters or fliers per minute. Such smaller scale equipment may beuseful for small business, home or medical usage.

4. allows manufacture of reactors utilizing different sources of heattreatment (steam in plant environment, electrical heating and organicfuel in small scale environments). In a typical bactericidal treatmentsystem, a temperature rise of a liquid to be treated is from about 25°C. to about 55° C. For example, in a reactor 30 cm high, with a dropletvelocity of 20 m/sec, the residence time will be about 15 mS. Thus,assuming an inlet temperature of 25° C. and an outlet temperature of 55°C., the temperature change is 30° C. over 15 mS, or about 2000° C. persecond. Typically, the temperature rise will not be linear, nor willequilibration require the entire reactor length, so that the maximumtemperature rise rate will be well in excess of 2000° C. per second.

The liquid to be treated may be degassed prior to processing, to preventaccumulation of non-condensing gasses within the steam treatment reactorand resultant alteration of the thermodynamic operating point. Further,by degassing the liquid prior to interaction with the steam, theinteraction with, and condensation of, steam on the fluid droplets isfacilitated. Preferably, non-condensing gasses are kept to less thanabout 50 mm Hg, and more preferably less than about 20 mm Hg.

Alternately or additionally to degassing prior to dropletization, thefluid may be degassed within a first region of the reactor, underrelatively high vacuum, after atomization, with subsequently reactionwith the steam in a second portion of the reactor. Thus, due to the gaswithdrawal in the upper portion, and condensation of the steam onto therelatively cooler droplet stream, steam will tend to flow from thesecond portion to the first portion of the reactor. Preferably, a baffleis provided between the two regions, with a relatively high density offluid droplets to be treated, present in the transition region betweenthe two portions, so that the steam condenses on the fluid droplets inthis region, maintaining the pressure differential while effectivelytreating the droplets. Thus, steam vapor diffuses toward the fluidinjection port.

In general, since the treatment chamber vessel operates at below 100°C., the pressure within the reactor will be below atmospheric pressure.For example with an operating temperature of 55° C., the chamber will beheld at approximately 0.5 atmospheres, or 380 mm Hg. Thus, the pressurein the chamber determines the operating temperature: if the pressure istoo high, the necessary temperature to achieve that vapor pressure ofsteam increases or steam condenses, raising the temperature of thereactor, and vice versa. This condition is considered “wet”. The controlover processing is thus primarily exerted by the net mass flow of steaminto the reactor. As stated above, a vacuum pump may be provided whichexhausts non-condensing gasses and may also withdraw excess steam,allowing an additional control parameter and further allowing anon-equilibrium steady state to exist.

The walls of the reactor vessel should be maintained at least at orslightly above the final operating temperature, to avoid condensation ofsteam on the wall and unnecessary product dilution. This may be done byany suitable heating system.

In fact, a number of methods are available to prevent droplets which areinsufficiently treated due to, for example, coalescence into largedroplets or statistical variations droplet size during atomization, fromcontaminating the treated product. For example, the droplets may beelectrostatically charged, and then normally diverted from a directpath. Droplets of too large a mass will be diverted less, and may beseparately collected. Alternately, an entire stream segment may bediverted if a flaw (untreated or untreatable portion) in the treatmentis detected. For example, an optical detector may detect a large droplettraversing the reactor and divert the outlet for a period of time toflush any contaminants.

It is believed that, as long as sufficient steam is present, smalldroplets will be effectively treated, while the persistence of bacterialcontamination through treatment is believed to be related to theexistence of large droplets. Thus, by eliminating or preventing large oruntreated droplets, the effectiveness of the treatment is maintained.

The reactor may also include a second form of anti-bacterial treatment,such as ultraviolet radiation, which may be supplied by ultravioletlamps illuminating within the reactor. Since the droplets are small, thelight penetration will be high, thus ensuring full coverage. Likewise,microwaves or other radiation may me used for auxiliary heating ofdroplets to the desired temperature, or for an electromagnetic fieldtreatment of the droplets. Where a particular strain of bacteria isproblematic, remediation efforts may be directed specifically towardthat strain. For example, complementary bactericidal systems may beemployed to reduce undesired strains.

The steam is generally derived from a boiler. Tight control oftemperature may require a high temperature boiler with a control valvenear the reactor vessel. In other words, in order to ensure adequateflow of steam into the reactor, an excess steam generation capacityshould be available from the boiler. Control is preferably effected nearthe reactor, to avoid time response delays, effects of conduit, oroscillation. The water in the boiler is preferably degassed to eliminatenon-condensable components.

In Pasteurization applications, especially for food products, the steamis injected into the reactor vessel through a number of steam injectionports, spaced along the path of the droplets within the chamber, so thatthe region distant from the fluid injection port maintains a constantvapor pressure of, e.g., about 0.5 ATM, and a temperature of, e.g. about55° C. Most of the energy to heat the droplets derives from the latentheat of vaporization of the steam, which is about 540 cal/ml steam.Thus, depending on the desired conditions, effective Pasteurization maybe obtained with between 2–5% by weight steam, condensed on the fluiddroplets to achieve the temperature rise. There are temperaturegradients in the reactor chamber, primarily near the injection nozzle.Since the steam condenses on the droplets, a partial vacuum is createdin the region around the droplet, until the droplet reaches atemperature in equilibrium with the pressure, e.g., around 55° C., andthus the vapor pressure equalizes. At this point, the net condensationceases, and the droplet remains in equilibrium.

Where the fluid to be treated contains other volatile compounds, such asethanol, such vapors may evaporate from the droplets, especially atelevated temperatures. This produces two effects. First, a boundarylayer is created by the net outward mass flow, which may impede steamcontact and heating. Second, depending on the temperature and pressure,the droplet may be effectively cooled by the net loss of this otherliquid component due to evaporation or boiling. Therefore, care must betaken to ensure that the fluid droplets do not reach the end of thereactor and pool prior to being raised to the desired temperature, orthat the temperature rise rate is insufficient. If it does undergo thedesired temperature rise rate, then the bacterial disruption effect isaccomplished. Otherwise, it may be necessary to inject alcohol vaporwith the steam to maintain equilibrium conditions in the reactor. It isnoted that the reactor may also be used to reduce or vary alcoholconcentrations of the fluid being treated, by varying the treatmentconditions. For example, alcohol vapors may be withdrawn and capturedthrough a vacuum pump, along with non-condensing gasses and some steam.This allows the production of a “light” alcoholic beverage, whilekilling yeast or other organisms.

It is noted that the reactor may effectively be used to treat milk,physiological solutions, fruit juices, blood plasma, blood serum, fruitand vegetable juices, potable water, egg white, beer, wine, egg yolk,sewage sludge, and atomized cheese.

Further, the reactor may be used for pharmaceutical processing,bioengineering processes, genetic engineering processes, vaccinesprocessing, enzymatic extractions and other treatment processes wherethermal shock is beneficial. These processes need not necessarilyinvolve disruption of bacterial membranes, and may be used for otherpurposes. Therefore, the reactor may be used to initiate chemicalreactions, activate coating powder or catalysts in chemical processes.

The present invention provides the advantage in pharmaceutical andbioengineering applications that the conditions of bacterialinactivation do not denature proteins, and may leave substantialbacterial structures essentially intact. Thus, in order to capture theproduct of bioengineering processes, the present method may be used, forexample as an alternative to ultrasonic disruption of cells. Theadvantage of the present process over ultrasonic treatments is that itis essentially instantaneous in operation, power efficient, and mayleave cells or cell fragments intact. This, in turn, allows the captureof antigenic structures for vaccines or the efficient processing offragile biomolecules.

The present process may also have utility in the processing of naturalor semisynthetic antibiotics, peptides or complex molecules. The presentsystem may be used, during gentle treatment, to stress the microorganisminto higher production of the desired compound(s), and to harvest thecompounds(s) by killing the organism and releasing the intracellularcontents, without denaturing proteins.

It is also noted that various non-biological compositions may have glasstransition temperatures in the 25–300° C. temperature range, andtherefore the present apparatus may be useful for using steam to rapidlyalter a crystalline state of, e.g., these polymers, copolymers, blockcopolymers or interpenetrating polymer networks. This rapid limitedheating may be advantageous for example, to rapidly initiate a chemicalreaction while maintaining a mechanical configuration of a bead, forexample, if the time constant for the chemical reaction is comparativelyfast with respect to the thermal diffusion time constant. Further, inlarger droplets, an external polymerized shell may be formed around anunpolymerized interior.

Other objects and advantages of the present invention will becomeapparent from a review of the drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the invention will be explained byreference to the drawings, in which:

FIG. 1 is a simplified diagram of a reactor according to the presentinvention;

FIG. 2 is a detailed diagram of a reactor according to the presentinvention;

FIG. 3 is a partially schematic diagram of a processing system accordingto the present invention;

FIG. 4 is a partially schematic diagram of a processing system showingdetails of sensor systems for control, according to the presentinvention;

FIG. 5 is a semischematic diagram of a processing system according tothe present invention employing continuous mode degassification;

FIG. 6 shows protein sediment mass (mg) dependence on temperature ofstainless steel surface at milk temperature of 20° C. and 35° C.;

FIG. 7 shows protein sediment mass (mg) dependence on temperature ofzirconium surface at milk temperature of 20° C. and 35° C.;

FIG. 8 shows protein sediment mass (mg) dependence on temperature ofstainless steel and zirconium surfaces for degassed milk during 30 min.at 20 mm Hg, at a temperature of 20° C.;

FIG. 9 shows protein sediment mass dependence on time of milkdegassification on a stainless steel surface at 70° C.;

FIG. 10 shows protein sediment mass dependence on time of milk string(control) on stainless steel surface at 70° C.;

FIG. 11 shows protein sediment mass dependence on surface temperaturefor mixed milk on stainless steel and zirconium surfaces;

FIGS. 12 and 13 shows reduction of E. coli in milk in the reactoraccording to the present invention under various conditions;

FIGS. 14 and 15 show schematic diagram of a Pasteurizer pilot plantaccording to the present invention as a flow diagram and process flowdiagram, respectively;

FIGS. 16A and 16B show a partial cross section and top view,respectively, of a Pasteurization reactor according to the presentinvention;

FIGS. 17A and 17B show an elevation and cross section view of aninjection nozzle according to the present invention; and

FIGS. 18A, 18B, 19A, 19B, 20A, 20B, 21A and 21B show time-pressure anddistance-temperature relationships, respectively, during operation ofthe Pasteurization reactor according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiments of the invention shall now be described withrespect to the drawings, where identical reference numerals in thedrawings indicate corresponding features.

EXAMPLE 1

FIG. 1 shows a simplified diagram of a steam condensation reactor vesselaccording to the present invention. The reactor is formed of an upperbody 203 and a lower body 201, with a seal 205 therebetween. A fluid tobe treated, which may be a growth medium, milk, or blood component, isdegassed according to conventional procedures, preferably to a level ofat most 50 mm Hg non-condensable gasses, and more preferably to a levelof no more than 20 mm Hg non-condensable gasses. The degassed fluidenters the reactor at approximately 22° C. through a conduit 201 havingan atomizer, which produces a spray of small fluid droplets, dispersedin the reactor space 210. The pressure in the reactor is held atapproximately 0.5 atmospheres by a vacuum control system 207, which isprovided with a baffle 206 to prevent withdrawal of fluid to beprocessed. The baffle 206 also serves to insulate the reactor space fromthe upper body 203. The reactor space is filled with steam, e.g.,substantially pure water vapor from steam injectors 202. The steam isprovided at equilibrium, and thus the vapor pressure of the steam at thetemperature of the reactor, i.e., approximately 55° C., is equal to thepressure of the reactor. Under such conditions, the steam will tend tocondense on the fluid droplets, releasing their latent heat ofvaporization, heating the droplets, until the droplets reach thetemperature of the steam. As the steam condenses, a partial vacuum iscreated around the droplet, causing a net mass flow into the droplet.Depending on the exact reactor conditions, up to 10% by weight of steammay be absorbed, but generally the amount will be limited to 2–5%.

The droplets are ejected from the atomizer at approximately 20 metersper second. The total height of the reactor space is approximately 30centimeters. Thus, the residence time of droplets within the reactor,before hitting the lower body 204, is at most about 15 mS. Therefore,the temperature of the droplets rises from 20° C. to 55° C. in about 15mS, thus yielding a temperature rise rate of at least about 2300° C. persecond. In fact, the maximum rise rate will likely be higher, becausethe steam equilibrates with the droplets before reaching the end of thereactor.

As the droplets hit the lower body 204, an accumulation and poolingtakes place, and the fluid drains from the reactor space through exitport 208, assisted by gravity.

EXAMPLE 2

FIG. 2 shows a reactor in more detail. The reactor is similar inoperation to the reactor detailed in Example 1. The reactor is formed ofa cover 302, and a shell 301. A lower conical base 313 is provided belowthe shell 301. In this case, the fluid to be processed is injectedthrough plenum 306, with an atomizer structure 312, which produces,e.g., 5 micron fluid droplets in a fast moving stream 309. Steam isinjected through a dual manifold system 305, which includes series ofcentral, upper injection ports 308, which provide a relatively high flowof steam near the atomizer structure 312, and a series of risers 304which allow for reduced macroscopic pressure gradients within thereactor. In order to prevent undesired preheating of the fluid, acooling jacket 307 is provided having circulating cooling water aroundthe plenum 306.

The fast moving stream 309 reacts with the steam injected through theupper injection ports 308 and the risers 304, and becomes a heated fluid310 at approximately the steam temperature. The heated droplets continuethrough the reactor, and reach equilibrium with the steam, asequilibrated droplets 311, and condense against the conical base 313 andexit the reactor through exit port 314. Preferably, a vacuum is drawn onthe exit port to exhaust any accumulation of non-condensable gasses fromthe reactor during operation, to maintain the reactor in a steady statecondition.

Table 1 shows various operating parameters of a preferred reactor designaccording to the present invention.

TABLE 1 Parameter Milk vapor Flow Kg/hr 1000 100   Pressure in entranceof 0.4  0.1 Processor Steam temperature in 40–100 Processor, ° C.Processor volume 0.1 48.8

EXAMPLE 3

FIG. 3 shows a bactericidal system incorporating the reactor 401described in Example 2. In this case, the fluid to be treated, e.g.,milk, is provided in a degassification chamber 402, provided with acontrol valve 411 to a vacuum pump 409. The fluid is transported with apump 407, through a valve 406, to the injection plenum of the reactor401. The reactor 401 is also connected to the vacuum pump 709 through aseparate valve 405 for startup cleansing of the reactor 401 andscavenging of non-condensable gasses. Pooled fluid accumulates at thebottom of the reactor 401, and is drawn to a processed fluid holdingtank 404, where it may be drained through vale 410. The fluid holdingtank is also connected to the vacuum pump through valve 408, to allow agradient for withdrawing processed fluid from the base of the reactor401. A steam generator 403 provides steam through control valve 412 tothe reactor 401, controlling the temperature in the reactor 401, e.g.,between about 40° C. and 90° C., depending on the desired treatmentconditions.

Tables 2, 3, 4 show experimental data for protein sediment mass based onvarious operating parameters of the reactor, as well as materialsemployed. It has been found that zirconium reactors producesignificantly less protein sediment than stainless steel reactors undersimilar operating conditions. It has also been found that increasedreactor temperature also results in increased protein sediment, for bothzirconium and stainless steel. Finally, it has been found thatdegassification of the milk reduces protein sediment on the reactor,possibly due to reduced oxidation during the process.

TABLE 2 Experimental Data for Protein Sediment Mass Dependence onSurface Temperature Milk Temp 20° Milk Temp. 35° Stain- less SteelStainless Temp Zirconium Steel Zirconium ° C. mg Temp ° C. mg Temp ° C.mg Temp ° C. mg 48 0.45 36 0.45 54 0.6 55 0.85 50 0.65 45 0.65 62 1.2564 1.45 62.5 2.2 56 1.2 70 1.85 71 2.55 65 3.6 63 3.8 79.5 3.85 78.53.45 64 2.5 64 2.5 90 4.6 87 4.4 76 4.85 74 4.9 96.5 5.35 96 4.7 78.57.25 85 7.0 81 9.2 94 8.25 89 9.45 93 9.35

TABLE 3 Experimental Data for Protein Sediment Mass Dependence onSurface Temperature Degassed Milk, 20° C. Stainless Steel Zirconium Temp° C. mg Temp ° C. mg 37 0.83 46 0.65 52 0.85 52 0.6 62 0.95 62 0.65 740.88 73 0.75 90 0.92 89 0.80

TABLE 4 Experimental Data for Protein Sediment Mass Dependence on OxygenContent In Milk for Stainless Steel Oxygen Saturated Milk Degassed Milk(20 mm Hg) Mixture time, min. mg Degassation time, min. mg 0 4.2 0 4.2 54.6 5 1.95 10 4.8 10 1.4 15 4.8 15 1.35 20 5.2 20 0.85 25 4.9 25 0.85 305.1 30 0.6

FIG. 6 shows protein sediment mass (mg) dependence on temperature ofstainless steel surface at milk temperature of 20° C. and 35° C.

FIG. 7 shows protein sediment mass (mg) dependence on temperature ofzirconium surface at milk temperature of 20° C. and 35° C.

FIG. 8 shows protein sediment mass (mg) dependence on the temperature ofstainless steel and zirconium surfaces for degassed milk during 30 min.at 20 mm Hg, at a temperature of 20° C.

FIG. 9 shows protein sediment mass dependence on time of milkdegassification on a stainless steel surface at 70° C.

FIG. 10 shows protein sediment mass dependence on time of milk stirring,without degassification, on stainless steel surface at 70° C., and thusserves as a control for the data of FIG. 9.

FIG. 11 shows protein sediment mass dependence on surface temperaturefor mixed milk on stainless steel and zirconium surfaces.

EXAMPLE 4

FIG. 4 shows a bactericidal system similar to the system described inExample 3, with the identification of elements for testing andcontrolling various conditions within the reactor system. In thissystem, the steam generator 403 is provided with a sight glass 428 fordetermining water volume, thermocouples T8 and T9 for determiningtemperature, pressure gage 437 and an electrical heater 428. Waterenters the steam generator 403 from reservoir 427 through valve 426.

The degassification chamber 402, in this instance, shows a system whichpartially replaces air, with argon 424, through control valve 411. Thus,according to this embodiment, the motive force for driving the mediumfrom the chamber 402 through the nozzle is the argon 424 pressure. Whileargon 424 is a non-condensable gas, the amount which dissolves isrelatively low during a treatment period. A thermocouple T10 andpressure gage 423 are also provided. A heater 430 is provided to heatthe outer shell of the reactor 401.

The steam is injected through a pair of control valves 412 a for anannular manifold and 412 b, for a riser manifold, into the reactor. Apair of thermocouples T6 and T7 are provided to measure the steamtemperature.

Within the reactor, a set of thermocouples T0, T1, T2, T3, T4 and T5allow determination of temperature gradients within the reactor atsteady state conditions.

To maintain vacuum conditions within the reactor, the vacuum pump (notshown in FIG. 4) acts through valve 422 and line 421 through water trap420 and valve 405. The vacuum also acts through valve 434 to draw pooledfluid from the reactor 401, through valve 431. Valves 432, 433 and 435allow use of sample 436, without disrupting reactor operation.

FIGS. 12 and 13 show results of testing the bactericidal effect, of thereactor system according to the present invention. In these figures:

-   -   n₀ is the initial concentration of E. coli (FIG. 13)    -   n_(V) is the concentration of bacterial which survive treatment    -   n_(k) is the concentration of killed bacteria    -   P_(H) ₂ _(O) is the pressure of steam in reactor    -   h is the heat of vaporization of water    -   T_(S) is the saturation temperature of steam in the reactor    -   R is the gas constant (8.31 g/kg K)    -   g_(st) is the steam flow    -   g_(H) ₂ _(O) is the flow of processed liquid    -   ∘ without degassification of chamber    -   ● with degassification of chamber    -   Δ with degassification of the liquid

FIGS. 12 and 13 thus show that bacterial kill to survive ratios increasewith increasing steam pressure (FIG. 12) and that degassification of thechamber improves bacterial killing as well (FIG. 13). FIG. 13 alsodemonstrates the effects of the relationship of fluid flow rate to steamflow rate.

Laboratory tests were conducted of various fluids containing E. coli, B.subtilis and mixed milk microflora. Tests were conducted of salinesolution, milk, egg yolks, and blood plasma. 90% heating of liquidoccurred within 1.5 to 2.0 mS. Table 5 shows results of E. coli insaline solution. The tests of other bacteria in other solutions producedsimilar results.

TABLE 5 surviving initial Sample End Temp Start Temp E. coli E. coliconc. No. T, ° C. T₀, ° C. n, % n₀, 10⁶/ml 1 50 13.2 1.4 2 51 13.6 1.340.035 3 52 11.0 0.1 0.035 4 52 11.4 1.3 0.21 5 52 11.4 1.5 6 52 11.40.078 0.035 7 53 23.2 1.3 8 56 40.0 1.0 0.11 9 63 37.0 0.018 0.11 10 6436.5 0.027 0.11 11 30 15.6 0.39 1.8 12 33 20.0 0.42 1.8 13 40 12.0 0.00614 41 24.7 0.46 1.7 15 42 23.8 0.37 1.8 16 42 17.5 0.43 1.7 17 44 19.80.32 1.7 18 50 32.8 0.007 0.22 19 50 31.0 0.006 0.22 20 52 30.6 0.0060.22 21 59 12.0 0.009 0.21

EXAMPLE 5

FIG. 5 shows a modified bactericidal system, as compared with Example 3,in which at least a portion of the degassification is performed in-line,rather than in primarily in batch mode. Further, the reactor forms apart of the degassification system.

A holding chamber 6 is provided for milk 5. A partially decompressed gasspace 4 is provided, acted upon by a low vacuum pump 8 through vacuumline 7, to vent 9. This acts as a first stage of the degassificationprocess. Fresh milk is fed to the holding chamber through an inletconduit 2 having a valve 63 and inlet port 3.

The partially degassed milk 11 is fed through fluid feed line 10 to afeed pump 53, through line 13, to a vortex degassification system 50,having vacuum pump 62 through vacuum line 61. The milk 51 swirls undervacuum conditions to exit port 52, and is pumped into the processor withpump 12. The milk is then atomized within the reactor vessel, of theprocessor shell 28 and the conical pooling region 32, behind a baffle55. The region proximate to the atomizer 54 is drawn under vacuum byvacuum pump 60 through line 59, to about 20 mm Hg pressure.

The atomized droplets 56 have a high surface area to volume ratio, anddegas readily under these conditions. The degassed droplets pass throughan aperture 57 of the baffle 55, and enter the main portion of thereactor vessel, coming into contact with steam at approximately 55° C.In this region, equilibrium is not achieved, and a net mass flow ofsteam will tend to be drawn upward through the aperture. However, sincethe droplets are cool, i.e., the milk stream is provided atapproximately 22° C. and the droplets are further cooled by thedegassification treatments, the steam will tend to immediately condenseon the droplets, causing a rapid heating.

The steam 29 is injected into the reactor through a vertical steamdistribution riser system 27, fed by steam distribution manifold 26,through steam injection line 24, pressure regulator 22, with relief port23, from steam generator 18 having steam space 119. The steam generatoris heated electrically by electrical heater 20, controlled by control 40with temperature sensor 41 and power source 42. Water is fed to thesteam generator 18 through water feed line 17.

Processed milk 58 contacts the conical neck 33 of the reactor and pools34 at the lower portion, and is withdrawn through outlet line 35,through pump 36, to processed milk outlet 37.

EXAMPLE 6

A pilot plant reactor system is shown in FIGS. 14–17. This system allowsoptimization of process parameters, and is capable of continuousoperation, however, as a pilot plant, is generally is operated with a 15liter fluid reservoir. The system operates on the principle of heatingdroplets using condensing steam in a vacuum chamber, which is held aconstant subatmospheric pressure by a vacuum pump. The pressure withinthe steam generator is measured with a compound pressure and vacuumgauge 612. The atomization of the fluid is implemented through a nozzle,into which the product is fed under the pressure, for example generatedby and inert gas (argon) source, at a pressure in excess of 4–5atmospheres, through gas/vacuum valve 613. The level of water within thesteam generator may be determine by viewing the glass level gauge 611.

The major components of the system, exclusive of controls, include asteam generator 601, a Pasteurization reactor 602, a raw product rank603, a Pasteurized product tank 604, a vacuum collector 616, a draintank 606, a condensate tank 607, and an inert gas feed-in system to theraw product tank 609.

The vacuum system includes water circuit pump 626 and vacuum oil pump620, which can operate individually or following the scheme: the gassesfrom the vacuum collector 616 are pumped out to a vacuum pump 620,and/or to a water circuit pump 626. In order to avoid watercondensation, or to diminish same, in an oil vacuum pump 620, a steamcondenser 621, which has its own water feed-in 622 and feed-out system,is installed between the reactor 602 which undergoes evacuation and thepumping system. The vacuum collector 616 drains to a condensate tank615.

Product steam processing control feedback is implemented through athermocouple (<1° C. resolution) and diaphragm pressure gauges (10 Paresolution). Thermocouples are installed in the water and steam units ofthe steam generator 601, in the reactor 602 near the nozzle as shown inFIG. 17, located near the top of the reactor 602 (seven in all) for thepurpose of gauging temperatures in a steam-droplet mixture at theproduct drain line 631 in the reactor 602, and in the tanks of raw 603and Pasteurized 604 products.

Pressure is measured in a steam collector 632 and in the bottom part ofthe reactor 634. In addition, it is possible to sample the steam-dropletmixture from the vacuum lines of the reactor 635, 636 for its subsequentanalysis on a mass-spectrometer 623 of the mass spectrometer system 639.The sample to the mass spectrometer 623 is passed through a massspectrometer sampler tank 618, the pressure of which may be determinedby pressure gauge 617. A vacuum pump 619 draws the sample gas into themass spectrometer sampler tank 618. The mass spectrometer is connectedto a magnetodischarge diode cooled pump 627.

Vacuum processing of the reactor 602 during operation is implemented intwo locations: in the upper part 635 of the reactor 602, near the nozzle637 for the purpose of degassing raw product from tank 603; and in thebottom part 636 through the reactor 602, around a system of shields,which is the main passage to the vacuum processing system.

Samples of the processed product are taken directly from the stream ofthe processed product, into disposable syringes, through the drain line606 of the reactor 602.

The Pasteurizer reactor system consists of a number of components. Anozzle 637 (sprayer) for atomizing milk or any other liquid product tobe Pasteurized, into drops. The nozzle 637 is of a standard,centrifugal, dismantling type. The outlet ring 646 of the nozzle 637 isreplaceable, its diameter being equal to 4.8 mm for the waterconsumption of 1 liter per second at a pressure 0.4–0.5 MPa and 2 mm forthe water consumption of 0.15 liters per second. The vortex segment 647of the nozzle 637 has the following dimensions: diameter equal to 27 mm,with the height of the cylindrical part equal to 6.5 mm. The vortexforming ring 645 has 6 triangular grooves 3.2×3.2 mm at an angle of 45°to the horizontal plane. There is an inlet 648 in the center of the ring645, the diameter of which is equal to 3.6 mm. When the inlet 648 isclosed, the nozzle 637 is operating as centrifugal. When the inlet 648is open, operates in a jet-centrifugal mode. The jet-centrifugal mode ofthe nozzle 637 fills the cone practically to capacity at a dispersionangle of 90°. The purely centrifugal mode of the nozzle 637 has thecenter of the cone empty, but the drops are of more homogeneousdimensions. The nozzle has a non-toxic rubber seal 643.

The body of the reactor, is attached to the shield 704 and the steamcollector 705, with inlets of 5 mm in diameter for steam dispensing thereactor. The placement of the inlets and their number are optimized byway of empirical testing depending upon the product consumption and thedimensions of its drops. The upper part of the steam collector 705includes two welded pipes 720 for dry (or slightly superheated for 10°C.–20° C.) food steam. The non-condensing gas is evacuated through thespace between the shield 704 and the outer body 721 of the Pasteurizerreactor 700. Connector 722 serves for evacuating the non-condensinggases from the bottom part of the Pasteurizer reactor 700 when there isno preliminary degassing of the raw product, and the degassing processis combined with deaeration. There is a circular groove 723 in thebottom part 706 of the body of the reactor 700 which serves forcollecting and discharging of the condensate, which is forming duringsteam condensing on the body of the Pasteurizer reactor 700.

The bottom of the Pasteurizer reactor 706 is designed for collectingdrops of the Pasteurized product, and its subsequent discharging intothe tanks 604, 606, 607. The bottom 706 is sealed with a rubber ropegasket 724. There are tubes 725 designed for discharging condensate fromthe circular groove 723 located on the body of the Pasteurizer reactor700 into the additional tank.

Food liquid to be treated in the Pasteurizer reactor 700 is broken upinto small drops (diameter of approximately 0.2–0.3 mm) by the nozzle637, on which steam condensing takes place. The drop heating speed andthe efficacy of Pasteurization is better when non-condensing gases areeliminated by way of vacuum degassing.

The siphon 726 is attached to the lower part 706 of the reactor's 700bottom, and has a welded seal for the thermocouple. The system featuresa siphon 726 to which a connection point 714 with a rubber ring seal727, has been welded in the upper part of its body. This rubber ringseal 727 enables sampling of the product be taken immediately) at thedrain line of the Pasteurizer reactor 700 by piercing it with adisposable syringe.

As shown in FIG. 14, raw product 523 with a temperature, for example of4° C. is fed into the tank 521 (constant level tank), and then is pumpedby the pump 518 through valve 517 into the recuperator 512, where it isheated, for instance, up to 44° C. The heated product is then directedthrough valves 508 and 505 into the deaerator 501, where it is degassed,with a vacuum through the valve 502. At this time partial evaporation ofthe product is taking place and it is cooled down, for instance to 34°C. The deaerated product is discharged from 501 through product pump506. Valve 504 and level sensor 547 provide the level, which isnecessary for normal operation of the pump 506. Pump 506 feeds theproduct through Valve 507 into the Pasteurizer 538. All pumps 518, 506,546, 530 can have similar parameters: capacity greater than or equal to1 m³/hour, with a pressure no less than 0.4 MPa.

The Pasteurizer 538 reactor is pumped out, reaching the level ofpressure approximately 10 Pa through valve 539, and is filled with dry,non-toxic, saturated steam reaching the level of pressure whichcorrelates with the temperature of saturation, for instance, 68° C.Steam Pressure controller 540, with the help of an automatic steam valve542, provides steam pressure at the inlet to the Pasteurizer 538 reactorwhich correlates with the specified temperature of saturation (68° C.).

The product is broken up to drops of specified dimensions, for example,0.3 mm, and is heated up by steam condensation from 34° C. to, forexample, 64° C. The heat-up speed is equal to up to 20–30 thousanddegrees Centigrade per second.

Through valve 545 and the level sensor 535, the Pasteurized product ispumped out by the pump 546, and is directed into the recuperator 512through valves 515, 513 and 514. The product is then cooled down in therecuperator 512 as low as, for instance 24° C. and is further dischargedinto the vacuum unit 532 through valve 534. Here the product is cooleddown due to the evaporation into the vacuum, until it reaches thetemperature of the raw product, e.g., 4° C.

The cooled down product is pumped out from the vacuum unit 532, throughpump 530, and is fed through a magnetic flow meter 529 and Valve 527either to the drain line 525, through which Pasteurized product isdischarged, or into the recirculation line 524 through valve 526, andthen into the constant level tank 521 through sight glass 522.

If the temperature of the cooled Pasteurized product is equal to thetemperature of the raw product, then dilution of the product with foodsteam is approximately equal to zero. The precise balance between thewater which is induced into the product and then removed from it, issustained by the Ratio Controller 519, by balancing gas pressure in thevacuum chamber 532.

During optimization of the Pasteurization system, automatic steam valve542 has to be monitored by the Steam Pressure Controller 540 at theinput to the Pasteurizer 538 reactor, by temperature monitor at theoutput from Pasteurizer 538 reactor and the thermal shock controller536. After this system is optimized, this valve will be controlled byone of the mentioned controlling mechanisms (most likely the thermalshock controller 536).

It is feasible to eliminate the preheating in the recuperator 512. Inthis case the product is fed through bypass 516 and farther on into thedeaerator 501 and into the Pasteurizer 538 reactor. The advantage ofthis procedure is that assuming that heat-up speed is equal, the maximumtemperature of the product at the output from the Pasteurizer 538reactor will be lower than in a system having a recuperator 512. Thedrawback, however, is that the extent of deaeration is reduced.

It is also possible to operate the system without the deaerator 501. Inthis case, the product is fed into the Pasteurizer 538 reactorimmediately through valve 508, while 507 is closed or through valve 508,valve 505, product pump 506, valve 507, while valve 504 is closed.

If recuperator 512 is not utilized, then there is no need to use productpump 546. In this case the Pasteurized product is discharged fromPasteurizer 538 reactor into the vacuum chamber 532 through valve 545 bythe force of gravity.

EXAMPLE 7

Using the reactor shown in FIGS. 14–17 and described in Example 6, thefollowing test was conducted. The reactor system, before operation, wassubjected to vacuum conditions by a vacuum water circuit pump for onehour to remove residual gasses, down to a pressure of 14 kPa. The steamgenerator was degassed by heating to 69° C. for one hour, and then allportions of the reactor were steamed at a temperature of 75–100° C.,with the vacuum pump turned off. After steaming, the condensate wasdischarged from the tanks, and the reactor and steam generatorhermetically sealed. The reactor was then subjected to partial vacuumand cooled down to 69° C. The steam heater was set to 150° C., with thesteam generator set to 65° C.

A physiological solution was initially processed by degassing for 45minutes. This solution was then fed through the reactor at a maximumrate of 50 liters per minute. The initial concentration of E. colibacteria in the solution was 8×10⁶ per ml, the initial temperature 20°C., and initial pH=5.1. After treatment, the bacteria were reduced to20% of starting values, the final temperature was 47° C., and finalpH=6.1. Nine liters of fluid were treated in 36 seconds, with aconsumption rate of 0.9 m³ per hour. The fluid was pressurized underargon with 4 atmospheres pressure. The average saturated steamtemperature within the reactor was 60° C.

The fluid tank was filled with a physiological solution containing E.coli from a sealed bottle. After fill-up, the physiological solution wasevacuated through a vacuum pump for a period of 45 minutes in order todegas the product. Argon was delivered into the source product tankunder a positive pressure of 4.0 atmospheres, and the maximum outflowrate, with the control valve being fully open, as established. Theduration for discharge of 9 liters of physiological solution was 36seconds, which corresponds to a consumption rate of 0.9 m³/hr. Theinitial portion of the processed product, about 1 liter, and the final 1liter portion were discharged into the drain tank, because the startupand completion periods may induce defects in the treatment or benon-uniformly treated. During the middle portion of the treatment, theproduct ported into the processed product tank, from which a 0.5 litersample was taken directly into a hermetically sealed glass vessel.

Upon completion of Pasteurization, the steam generator was turned off,and argon was delivered into the reactor and the product was discharged.After discharge, the system was cleaned with an alkaline solution,followed by rinsing with distilled water. The system was disassembled,examined, subjected to boiling of the disassembled reactor, tanks andremovable parts of the vacuum system for 5 hours. After cleaning thesurface, the system was reassembled.

Based on an analysis of thermocouple data, it is apparent that heatingof the droplets occurs within an interval of 70 mm from the nozzleorifice, with a gradient of 0.55° C. per mm, as shown in FIG. 18B. Dueto the high fluid flow rate, and a relative insufficiency of the powerof the boiler, the Pasteurization process was non-stationary, as shownby the divergence of P and Ps in FIG. 18A. The steam pressure in thesteam generator during the process was lower than the saturationpressure in the steam generator by a factor of 1.0–1.5 kPa. Thetemperature in the droplet cone was about 60–50° C., i.e. the steam waswet.

As was demonstrated by further tests, wet steam is not conducive tooptimal results

EXAMPLE 8

In order have the system described in FIGS. 14–17 operate in astationary mode, the following changes were made from the proceduredescribed in Example 7:

(1) The power of the steam generator was increased to 12 BTU, togetherwith a superheater it amounted to 15 BTU.

(2) The centrifugal jet injector, having a nozzle diameter of 4.8 mm,was replaced by a centrifugal jet injector having a nozzle diameter of2.0 mm, thus reducing flow rate.

(3) The geometry of the steam distributor was changed.

(4) Sample testing was performed using a disposable syringe duringPasteurization.

A test was conducted as follows: Starting conditions: 10⁶ E. coli perml, temperature 21° C., pH=5.37, fluid volume 15 liters. Finalconditions: less than 2 E. coli per ml, i.e., 2×10⁻⁶ times the startingamount (the limit of the sensitivity of the detection method),temperature 64° C., pH=6.8. The consumption rate was 150 liters perhour. The steam saturation temperature Ts=65° C., with the temperatureof the superheated steam being 77° C.

The tests on the air-tightness of the system before the experimentproved that there was no gas in-leakage. The process was conducted witha temperature in the steam generator being equal to 65° C. The steam inthe heater was about 10° C. higher than the saturation temperature.Before injecting the liquid into the reactor, the pumping rate waslowered to such level, so that 10% of the power capacity of the steamgenerator was expended. When the fluid was injected, the steam generatorautomatically switched to 100% power mode. The reduced power mode wasmaintained for 5 min. prior to commencing treatment.

Under these conditions, a stationary mode of operation was achieved for250 seconds, as shown in FIG. 19A. The difference between pressure inthe reactor P and the saturation pressure Ps did not exceed 100 Pa. Thetemperature gradient at the surface of the cone was 2° C. per mm. asshove in FIG. 19B.

EXAMPLE 9

Further tests pertaining to B. subtilis and milk were performed in amanner similar to that set forth in Examples 7 and 8.

The following method was conducted:

(1) preliminary vacuum treatment of reactor was conducted for one hour.

(2) gas in-leakage was tested using pressure sensors (gas in-leakagetolerance was approved for no more than 100 Pa during 6 minutes, theduration of the test).

(3) parts of the reactor were steamed with superheated steam having atemperature of 100–150° C. for 30 minutes.

(4) condensate was discharged.

(5) The raw product was vacuum pumped into the tank for a duration of 5minutes.

(6) The raw product was treated in the reactor and test samples drawn.

(7) The equipment was cleaned.

The tests were conducted under different conditions with respect tovacuum level and gas in-leakage.

B. subtilis was present at a starting concentration 8×10⁴ per ml,initial liquid temperature 20° C., initial pH=6.67, volume of solutionequal to 15 liters. B. subtilis final concentration 0.23–0.28% oforiginal concentration, final temperature 66° C., final pH=6.67,consumption rate 150 liters per hour. The saturation temperature Ts was67° C., and the temperature of the superheated steam was 130–115° C. Thedegassing of the steam generator was conducted at a power equal to about30% of the actual power of the steam generator.

Under these circumstances, the steam pressure P varied over time, aswell as the saturation pressure Ps. The process was not stationary, asshown in FIG. 20A, and the steam was wet, with a Ps-P of about 1.5 kPa.The results are therefore similar to those obtained for Example 6, andthe remaining amount of active bacteria is approximately 25% of startingvalues, even with a relatively high temperature gradient of 3° C. permm, as shown in FIG. 20B.

EXAMPLE 10

Using a method similar to that of Example 9, the following results wereobtained. A starting concentration of 10⁴ per ml of E. coli and milkmicroflora in milk was measured. The initial temperature was 20°,initial pH=6.67, with a volume of 15 liters.

The system produced a reduction to 2%, 1.5% and 3% of starting bacterialconcentrations, with a final temperature of 60.5° C., final pH=6.87, anda consumption rate of 150 liters per hour. The saturation temperature Tswas 62° C., with the temperature of the superheated steam being between170–115° C.

During Pasteurization process, there is a simultaneous increase ofpressure in the Pasteurizer P and the steam generator Ps, indicatingthat gases are emitted from the liquid that is undergoingPasteurization. Due to the low throughput, which corresponded toapproximately to 7% of the actual power capacity of the steam generator,and to the high content of gases in the milk, there is a great increaseof non-condensing gases in the reactor, reaching a pressure P of 2.5kPa, as shown in FIG. 21A. FIG. 21A also shows that the process wasinitially stationary, and later, at about 180 seconds, becameprogressively non-stationary, until the process was almost over. Allthese factors result in reduced efficacy. Further, the initialtemperature of the milk was 20° C., at which temperature fat globulesare solid, probably contributing to the negative effect, though thenon-condensing gasses are primarily responsible for the failure toachieve sterilization.

The temperature gradient was 1.7° C. per mm, as shown in FIG. 21B.

In a prior study, milk containing E. coli and the microflora of about10⁵ per ml underwent steam heating in an identical process, starting atT=21° C. and being raised to 62° C., which produced complete killing ofE coli, down to less than about 2×10⁻⁵ per ml. That test was conductedon one liter of milk which was injected into a 60 liter reactor during 3seconds, without vacuum, i.e. in a stationary mode with a negligiblepressure variation in the reactor due to release of the gases dissolvedin the milk.

Therefore, it can be seen that the rate of withdrawal of non-condensinggases in liquid undergoing steam processing is an important feature ofthe process. When the speed of withdrawal is low, gas is collected inthe reactor, and the amount of steam which condenses on the milkdroplets is reduced. However, when the speed of withdrawal is high,steam becomes wet, and this significantly deteriorates the efficacy ofthe process.

The best results are obtained in a hermetically sealed unit using drysaturated steam. Preliminary degassing of the milk reduces theoutgassing problem.

EXAMPLE 11

The apparatus as shown in FIGS. 14 and 15 are used to Pasteurize beer.The initial temperature is 4° C., with a final temperature of 40° C. Thebeer is degassed to 50 mm Hg prior to treatment and recharged withcarbon dioxide gas, after treatment and cooling. For a standard product,the steam includes about 4% ethanol to maintain alcohol level. For a lowalcohol product, steam without ethanol is employed. Low alcohol productsare further subjected to flash cooling and alcohol removal under vacuumafter processing. The resulting product may be filtered to removesediment.

EXAMPLE 12

A standard blood pheresis apparatus, available from Johnson & Johnson,is employed in an extracorporeal reactor system to remove and separateblood components. The leukocyte-rich fraction is diluted 1:10 indegassed 4° C. normal saline, and passed through a reactor similar tothat shown in FIGS. 14 and 15, although smaller. For example, thereactor is 120 mm high. Droplets are atomized as 75–100 microns. Steamis injected into the reactor to reach a maximum temperature of 35–40° C.flow through the reactor is about 100 ml per minute. The processedleukocytes are reinfused into the patient. Fluid overload is limited byretaining plasma from the pheresis system, as necessary (which may bereinfused later), and limiting the duration of the treatment. Leukocytesmay also be concentrated from the treated stream and excess fluideliminated.

This treatment may be used to treat blood borne diseases, immunologicaldisorders and syndromes, AIDS, CFS, viral diseases, leukemias and blooddisorders.

EXAMPLE 13

The apparatus as shown in FIGS. 14 and 15 is used to process bacterial,fungal or cell culture medium. The cells are initially provided at atemperature of 4–45° C., depending on type. The medium is initiallydegassed to 50–100 mm Hg non-condensing gasses, with most of theremaining gas as oxygen, unless the culture is anaerobic. A mild,non-lethal treatment provides a temperature rise of about 2–15° C.,while a lethal treatment provides a temperature rise of about 15–50° C.Temperature rise rate may be controlled as well, with larger rates beingstronger treatments.

EXAMPLE 14

A skin treatment device is provided. The effected areas are separatedfrom the environment by an enclosure, having uniformly spaced steamvents. The enclosure is evacuated to a vacuum of about 0.5 atmospheres,with non-condensing gasses replaced with water vapor. A soft gasketmaterial rests against the skin at the periphery of the region to betreated. The treatment consists of the rapid infusion of steam at about50° C. into the vacuum space, directed at the skin. The steam treatmentoperation lasts less than 0.25 second, and may be repeated. Theconditions of the treatment are controlled to prevent tissue burning andmass necrosis.

It should be understood that the preferred embodiments and examplesdescribed herein are for illustrative purposes only and are not to beconstrued as limiting the scope of the present invention, which isproperly delineated only in the appended claims.

1. A method for inactivating microorganisms in a fluid contaminated withmicroorganisms, comprising forming a suspension of droplets of the fluidwithin an atmosphere comprising a condensable vapor with a high latentheat of vaporization, wherein a temperature of the droplets is below aboiling point of the vapor, such that the droplets are rapidly heated bycondensation of the vapor and release of the latent heat of vaporizationthereof, controlling a supply of vapor and a partial pressure ofnon-condensing gasses in the chamber, to maintain steady state processconditions over a sustained period of time, to inactivate a significantportion of the microorganisms in the processed fluid, wherein the timeand temperature conditions of processing are insufficient to inactivatethe microorganisms by a mechanism of thermal denaturation, andmaintaining processed fluid separate from contaminated fluid.
 2. Themethod according to claim 1, wherein the droplets move through the vaporalong a common axis at a high velocity.
 3. The method according to claim1, wherein the fluid is an aqueous fluid.
 4. The method according toclaim 1, wherein the vapor comprises steam.
 5. The method according toclaim 1, wherein the fluid is degassed prior to dropletization, toreduce formation of a rate limiting boundary layer.
 6. The methodaccording to claim 1, wherein the fluid is an aqueous fluid, the vaporcomprises stream at subatmospheric pressure, and the maximum processtemperature of the fluid is 65° C.
 7. The method according to claim 1,wherein the heating rate of the fluid is at least 1400° C. per second.8. The method according to claim 1, wherein the droplets are heated byat least 10° C.
 9. The method according to claim 1, wherein the fluidcomprises a beverage.
 10. The method according to claim 1, wherein thefluid droplets have an average diameter of less than about 0.3 mm. 11.An apparatus for treating a fluid contaminated with microorganisms,comprising: a chamber; a vapor injector, injecting a condensable vaporhaving a high latent heat of vaporization within said chamber; a nozzle,forming a suspension of droplets of the fluid within said chamber,having wherein a temperature of the droplets is below a boiling point ofthe vapor, such that the droplets are rapidly heated by condensation ofthe vapor and release of the latent heat of vaporization thereof, a pumpfor altering an amount of non-condensable gasses in said chamber; acontrol for controlling a supply of vapor and an amount ofnon-condensing gasses in the chamber, to maintain steady state processconditions over a sustained period of time, the control establishingtime and temperature conditions which are insufficient to inactivate themicroorganisms by a mechanism of thermal denaturation, whileinactivating a significant portion of the microorganisms in theprocessed fluid; and an outlet port for removing processed fluid fromthe chamber and maintaining processed fluid separate from contaminatedfluid, whereby a bulk fluid can be processed without recontamination.12. The apparatus according to claim 11, wherein the nozzle expels thedroplets through the vapor along a common axis at a high velocity. 13.The apparatus according to claim 11, wherein the fluid is an aqueousfluid.
 14. The apparatus according to claim 11, wherein the vaporcomprises steam.
 15. The apparatus according to claim 11, furthercomprising a vacuum source for degassing the fluid prior todropletization, to reduce formation of a rate limiting boundary layer.16. The apparatus according to claim 11, wherein the fluid is an aqueousfluid, the vapor comprises stream, and the maximum process temperatureof the fluid is 65° C.
 17. The apparatus according to claim 11, whereinthe heating rate of the fluid is at least 1500° C. per second.
 18. Theapparatus according to claim 11, wherein the droplets are heated by atleast 10° C.
 19. The apparatus according to claim 11, wherein the fluidcomprises a beverage.
 20. The apparatus according to claim 11, whereinthe nozzle forms fluid droplets having an average diameter of less thanabout 0.3 mm.
 21. The apparatus according to claim 11, wherein the vaporcomprises steam, further comprising a boiler for generating steam, asuperheater for heating the steam above an equilibrium condensationtemperature.
 22. The apparatus according to claim 11, further comprisinga control for maintaining treatment conditions of the droplets within apredetermined range.
 23. The apparatus according to claim 11, furthercomprising a port for removing processed fluid from said chamber duringheating of droplets.
 24. The apparatus according to claim 11, furthercomprising a vacuum source for degassing the fluid prior todropletization to no more than 50 torr partial pressure ofnon-condensing gasses.
 25. The apparatus according to claim 11, whereinnon-condensing gasses are continuously withdrawn from said chamberduring heating of droplets.